Absorbent body for an absorbent article and method of producing an absorbent body

ABSTRACT

A method of producing an absorbent body includes the steps of passing a first cut-out from a first web material through a nip and passing a second web material through the nip whereby the cut-out from the first web material overlays the second web material as the cut-out and the second web material pass through the nip. One of the following is performed as the cut-out from the first web material and the second material together pass through the nip: forming a fold line in the second web material at the peripheral edge of the cut-out of the first web material and forming a second cut-out from the second web material having substantially the same shape as the first cut-out from the first web material.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.10/049,891 filed Jul. 8, 2002, which is hereby incorporated by referencein its entirety.

BACKGROUND

The present invention concerns an absorbent article comprising asegmented absorbent body and a method of producing an absorbent body, inparticular a segmented absorbent body. The absorbent body is preferablyarranged between a liquid-permeable cover layer and a liquid-impermeablebacking layer.

It is known from the state of the art how to produce absorbent articlescontaining the absorbent bodies. As a rule, these absorbent bodies arearranged between a liquid-permeable cover layer and a liquid-impermeablebacking layer. Such absorbent articles include, for example, menstrualhygiene napkins, disposable diapers, training diapers and incontinencearticles for adults as well as similar articles. As a rule, theabsorbent bodies of the traditional type contained in these absorbentarticles contain pulped cellulose or sheeting materials ofcellulose/synthetic fiber blends as the absorbent material.

These materials are supposed to serve to absorb body fluids such asmenstrual fluid and retain them in a napkin. The menstrual fluid shouldpreferably remain inside the absorbent article even under pressure andif possible it should not be detectable from the outside. The absorbentarticle and in particular the absorbent body in the absorbent articleshould prevent the secreted body fluids from soiling the wearer's bodyand/or spotting the adjacent items of clothing.

The sheeting materials used for the absorbent material are eitherarranged continuously (i.e., they cover the total length of the napkinor they form rectangular inserts, for example) or they may have cutouts.The cutouts are preferably arranged in a top layer of the absorbentmaterial and should serve to convey the fluid away from the body of thewearer of the absorbent article as rapidly and efficiently as possibleand to release it downward into the other absorbent and storing layersof the absorbent article.

There are several possibilities of storing the fluid delivered in theabsorbent article. One of these possibilities is to convey the fluidsecreted as rapidly and directly as possible to a lower area of thearticle which is preferably arranged directly above theliquid-impermeable backing layer, from whence the fluid is thendistributed in the longitudinal direction. As soon as this bottomabsorbent distributor layer becomes saturated with the fluid secreted,the absorbent layers closer to the wearer's body then become saturatedwith the fluid.

Another possibility is for the secreted body fluid to be distributed asrapidly as possible in the longitudinal directions of the napkin, fromwhence in the remaining course it then diffuses toward the side of theabsorbent article facing away from the wearer's body.

Apart from providing a cutout in an upper area of the absorbent materialin an absorbent article, there are various other possibilities forimproving the distribution of fluid in an absorbent article. Thesepossibilities involve, for example, providing various layers within theabsorbent article to function as flow layers, storage layers, transferlayers or distributing layers. Such layers may be defined by differentmaterials, for example. Another possibility is to provide embossed linesin a layer of the absorbent material in an absorbent article throughwhich the fluid is guided in predetermined and preferred paths, thuspreventing the area of the absorbent article exposed to the fluid frombecoming saturated.

Another possibility of preventing leakage and promoting penetration ofthe secreted fluid into the interior of the absorbent material is toprovide elastic or elevated side areas (cuffs) which should preventleakage at the sides.

With the absorbent articles described above, it is also important thatthe absorbent article is adapted to the shape of the wearer's body,preferably conforming to the shape of the wearer's body, so that thewearer is not hindered by the absorbent article. It is especiallypreferable for the absorbent article not to be perceived by the wearerat all. Furthermore, the absorbent article should be prevented fromrubbing against the wearer's body in a manner that would be unpleasantfor the wearer, even leading to red and irritated skin. There have beenvarious proposals for achieving such an optimum suppleness andadaptability to the wearer's body. Many of these proposals concern theuse of materials that are already rather supple anyway and thereforeoffer increased comfort for wear. However, such materials are often lesssuitable than an absorbent material for their actual function. A typicalabsorbent material such as coform will have a certain stiffness whichcan be reduced only by also surrendering certain advantageous absorbentproperties.

SUMMARY

One object of the present invention is to provide an absorbent articlethat does not have the abovementioned disadvantages according to thestate of the art. In particular, one object of the present invention isto provide an article that prevents in particular leakage of secretedfluid into the side areas of the absorbent article (side leakage) in animproved manner.

Another object of the present invention is to provide an absorbentarticle which permits especially good suppleness and individualadaptation to the wearer's body.

Finally, another object of the present invention is to reduce thestiffness of a continuous web of material in such a manner that it leadsto an improved suppleness and better adaptation to the wearer's body.

The above-mentioned objects are achieved by the absorbent articlecharacterized in Claim 1, as well as by the method characterized inClaim 29. Accordingly, an absorbent article is provided, comprising anabsorbent body having one or more layers, where said absorbent body issegmented by at least one dividing seam in at least some partial areas.

The term “segmented” as used here is understood to refer to thesubdivision of the absorbent body into subareas, i.e., segments, definedby at least one dividing seam.

The term “dividing seam” is understood to refer to the areas of amaterial processed for separation. The term “processed for separation”is understood here to refer to the separation methods known in the stateof the art by means of which individual areas of a material layer can beseparated from one another. “Processing for separation” thus produces ingeneral dividing seams in these materials, e.g., punched or cut lines.

The dividing seam may consist of a continuous or interrupted dividingline. If the dividing seam is executed in the form of an interrupteddividing line, the different areas of material are still joined togetherby bridge areas. In addition, a dividing seam can be worked through theentire thickness of one or more layers of material or through onlypartial areas of the thickness or one or more layers of material. Thelatter is preferred if the layer of material is still to form a unit.

Providing an absorbent body which is segmented by at least one dividingseam in at least partial areas yields an absorbent article whichachieves optimum suppleness and individual adaptation to the wearer'sbody. The segmentation, which forms intended breaking points, eliminatesor reduces the stiffness of the absorbent material in an inventivemanner, leading to improved suppleness. In addition, the dividing seamsimprove the rapid penetration of the secreted fluid into the depth ofthe absorbent body, thus preventing side leakage in an improved mannerand thereby also preventing soiling of the wearer's body and/orclothing.

The dividing seams yield stable individual elements that emboss andcompress the absorbent body. Thus, areas of different density are formedwithin each individual element. Density gradients are formed along thedividing seams, optimizing fluid transport. On the whole, the absorbentbody is especially compressed in the area around the dividing seams. Thefluids such as menstrual fluid to be absorbed by the absorbent body mayconsist of various components which have different properties and aretransported to different extents through a uniformly structuredabsorbent body. Due to the presence of areas of different density anddue to the density gradient prevailing along the dividing seams, it ispossible for each fluid component to find an area especially suitablefor its transport.

To further improve upon the side leakage protection, it is especiallypreferable to increase the number of dividing seams in the edge area ofthe absorbent body.

The segmentation of the absorbent body yields many small individualelements that are stabilized on all sides and are especially preferablyapplied to a flexible elastic substrate. Therefore, the segments aredisplaceable with respect to one another. Thus, the absorbent body canbe adapted especially well to the body contours of the wearer.

In a preferred embodiment of this invention, the absorbent body has atleast two layers, with at least one of the layers being segmented. Thispermits an optimum combination of the properties of the segmented layerwith those of an unsegmented layer, for example.

Preferred shapes for the segments created by the dividing seams in theabsorbent body may be squares and/or diamonds and/or circles as well asany other suitable geometric shape. In another especially preferredembodiment of this invention, the absorbent body is designed with atleast two layers, where at least one layer of the absorbent body facingthe wearer's body is smaller than at least one other layer of theabsorbent body facing away from the wearer's body.

The layer of the absorbent body facing the wearer's body faces thewearer's body when the absorbent article is in use and is thus arrangedover the layer of the absorbent body facing away from the wearer's body.The latter faces away from the wearer's body when the absorbent articleis in use.

Providing an absorbent body which is designed with at least two layersyields various functions as follows, where at least one layer facing thewearer's body and at least one layer facing away from the wearer's bodyare formed, and at least one layer of the absorbent body facing thewearer's body is smaller than at least one other layer of the absorbentbody facing away from the wearer's body, so that the entire absorbentmaterial has a predetermined “intended breaking line”:

-   -   providing an “intended breaking line” as defined above yields        optimum suppleness and individual adaptation to the wearer's        body,    -   providing the two-layer absorbent body where the layer of the        absorbent body facing the wearer's body is smaller than the        layer of the absorbent body facing away from the wearer's body        creates a liquid storage area in the center of the napkin to        improve the side leakage protection,    -   preferably the minimum of one layer of the absorbent body facing        the wearer's body has less than 70% of the area of the minimum        of one layer of the absorbent body facing away from the wearer's        body; even more preferably, the minimum of one layer of the        absorbent body facing the wearer's body has less than 50% of the        area of the minimum of one layer of the absorbent body facing        away from the wearer's body; even more preferably, the minimum        of one layer of the absorbent body facing the wearer's body has        less than 30% of the area of the minimum of one layer of the        absorbent body facing away from the wearer's body.

The minimum of one layer of the absorbent body facing the wearer's bodyis formed by the shaping methods known in the state of the art. It isespecially preferable for the minimum of one layer of the absorbent bodyfacing the wearer's body to be punched out or cut out.

The term “layer” as used in the present invention includes layers of oneor more materials as well as multilayer composites such as laminates.

In an especially preferred embodiment of the present invention, one ormore layers arranged beneath and/or above the minimum of one layer ofthe absorbent body facing the wearer's body has been processed forseparation and thus segmented along the same contours as the minimum ofone layer of the absorbent body facing the wearer's body.

The shaping of the minimum of one layer facing the wearer's body can beperformed here by one of the methods known in the state of the art, suchas cutting off or out, molding, punching, etc. The layer of theabsorbent body facing away from the wearer's body as well as the layersof the absorbent body above and/or below that are processed forseparation, e.g., cut or punched.

In another especially preferred embodiment of the present invention, theminimum of one layer of the absorbent body facing the wearer's body andone or more of the layers arranged above and/or below that are processedfor separation along the same contours as the minimum of one layer ofthe absorbent body facing the wearer's body.

According to an especially preferred embodiment of the presentinvention, not only the minimum of one layer of the absorbent bodyfacing the wearer's body is punched out or cut out, but also additionallayers which may be present in the napkin are also punched or cut out.

Apart from the minimum of one layer of the absorbent body facing thewearer's body, it is especially preferable for the layers of theabsorbent body facing away from the wearer's body beneath that to beprocessed for separation. However, then preferably the “frame grid” ofthe minimum of one layer of the absorbent body facing the wearer's bodyremains in the napkin, while the “punched grid” of the minimum of onelayer of the absorbent body facing the wearer's body is removed in anycase. The term “frame grid” as used here is understood to refer to thepart of a layer of material located outside a dividing seam provided init, e.g., a punched or cut area, and forming a part of the absorbentarticle. In other words, the minimum of one layer of the absorbent bodyfacing away from the wearer's body is segmented by separation processinginto a frame grid and an area enclosed by the frame grid. The term“punched grid” here is understood to refer to the part of a layer ofmaterial located outside the dividing seam, e.g., the punched or cutarea, and not forming part of the absorbent article. The “frame grid” ofcourse has a preferred shape for the absorbent article, which in thepresent case preferably corresponds to the overall shape of theabsorbent article. This yields the absorbent body according to thisinvention, comprising at least one layer facing the wearer's body whichis smaller, due to removal of the “punched grid”, than the minimum ofone layer arranged at a distance from the body, likewise processed forseparation, e.g., cut or punched, and where the “frame grid” forms apart of the absorbent article, however.

By providing an absorbent body having at least two layers, where theminimum of one layer of the absorbent body facing the wearer's body hasa smaller area than the minimum of one layer of the absorbent bodyfacing away from the wearer's body, and due to the fact that the layerof the absorbent body facing away from the wearer's body has beenpunched and/or cut in a manner corresponding to the punched or cut outarea of the layer of the absorbent body facing the wearer's body, thisprovides an absorbent article which eliminates the stiffness of acontinuous web of material due to the cutouts and/or punched areas, inaddition to an optimum suppleness and an individual adaptation to thewearer's body and an improvement in side leakage. It is known that thepreferred absorbent material used in absorbent articles has a certainstiffness. If an entire web of material of such an absorbent material isprovided in an absorbent article, as is usually necessary to guaranteeadequate absorption and storage properties of the absorbent article,this leads to a stiffness of the absorbent material which makes theabsorbent article uncomfortable to wear on the whole.

This leads to a suboptimal suppleness, and adaptation to the individualwearer's body is not guaranteed. The stiffness of a continuous web ofmaterial can be eliminated in an inventive manner by the cutout/punchedout areas in the minimum of one layer of the absorbent body facing awayfrom the wearer's body. This leads to a great improvement in supplenessand the possibility of an individual adaptation to the body of thewearer.

Furthermore, the permeable areas of the cutout or punched out areasfacilitate more rapid penetration of the secreted fluid deeper into thenapkin and thus prevent side leakage in an improved manner and thusprevent soiling of the wearer's body or the adjacent clothing in thearea of the absorbent article and thus contribute toward a reduction insurface moisture. This effect is increased by the altered capillarity ofthe materials in the immediate vicinity of the punched out/cutout areas.The material is compressed there', thus increasing the capillarity. Thiscauses a more effective fluid transport into these areas which thusfunction as “intended penetration areas” where the fluid is transportedespecially rapidly and effectively.

Preferably the minimum of one layer of the absorbent body facing thewearer's body, which is smaller than the minimum of one layer of theabsorbent body facing away from the wearer's body, is in the shape of anoval. Other possible shapes include a rectangular shape, a tongue shape,a triangular shape, a circular shape, a trapezoidal shape or anhourglass shape. Any other geometric shape is also conceivable for thepresent invention, as long as it meets the requirements specified above.

In another preferred embodiment of this invention, additional dividingseams, e.g., cut-out or punched-out areas, are provided in the minimumof one layer of the absorbent body facing the wearer's body and/orwithin one or more layers of the absorbent body arranged above and/orbelow that. These additional dividing seams, e.g., cut-out orpunched-out areas, are arranged inside the areas of the above-mentionedlayers determined by the shape of the minimum of one layer of theabsorbent body facing the wearer's body. For example, the minimum of onelayer of the absorbent body facing the wearer's body may have an ovalshape and may have additional oval cut-out or punched-out areasconcentric with the former. The additional layers of the absorbent bodymay also have these additional oval punched out areas arrangedconcentrically, where the corresponding punched areas in the differentlayers essentially coincide.

The additional dividing seams, e.g., cut-out or punched-out areas in thevarious layers of the absorbent body, improve the suppleness andadaptability to the body of the individual wearer through the resultingsegmentation, while also improving the fluid transport within theabsorbent article.

Preferably the absorbent article according to the present inventioncomprises the following components:

-   -   a) a liquid-permeable cover layer and    -   b) a liquid-impermeable backing layer, where the absorbent body        is arranged between the cover layer and the backing layer.

The minimum of one layer of the absorbent body facing away from thewearer's body preferably has elongated side areas. The cover layerand/or the backing layer may extend laterally outward from the elongatedside parts of the absorbent body to provide a pair of elongated sideedges for the absorbent article. The cover layer is arranged on the sidefacing the wearer's body and should be arranged next to the wearerduring use. The backing layer is arranged parallel to the cover layerand should be next to the wearer's underwear garment when being used.

The cover layer may be manufactured from materials known in the state ofthe art. They should be liquid permeable. Known materials include, forexample, card weaves and spunbonded nonwovens made of polyester,polypropylenes, polyethylene, nylon or other heat-bonded fibers. Otherpolyolefins such as copolymers of polypropylene and polyethylene,linear, low-density polyethylene fiber nonwovens which are finelyperforated or mesh-like materials are also suitable. Other suitablematerials include composite materials of polymers and a nonwovenmaterial. The composite layers are usually formed by extrusion of apolymer on a layer of a spunbonded nonwoven to form an integral layer.This material is preferred, because the outer surface is not irritatingto the skin of the wearer and it has a pleasant feel.

With regard to the above-mentioned cover layer, it is also advantageousthat this cover layer has the following features. In general, a coverlayer is provided to achieve the greatest possible comfort and greatadaptability to the wearer's body and should divert fluid to the bodyunder it. The cover layer may be constructed of a relativelynonabsorbent liquid-permeable material, where the cover layer may beconstructed of any woven or nonwoven material through which body fluidwhich contacts its surface can flow easily. The cover layer ispreferably made of a material that permits the passage of fluid withoutdrawing the fluid horizontally in parallel to the cover layer to anygreat extent. In addition, the cover layer should retain little or nofluid in its structure, so that a relatively dry surface is providednext to the wearer's skin. In general, the cover layer is a single layerof a material with a width sufficient to cover the surface of theabsorbent body facing the wearer's body. The cover layer preferablyextends to the longitudinal edges and is bonded to the backing layer.The cover layer may be bonded to the backing layer using any knownmethod which does not leave any hard or uncomfortable residues thatwould annoy the wearer. Those skilled in the art are familiar withmethods of bonding the various materials and for bonding other possiblematerials in the absorbent article according to the present invention,including the use of pressure-sensitive adhesives, hot-melt adhesives,two-sided adhesive sheets, ultrasonic welding and heat sealing, to namebut a few. Adhesives such as hot-melt adhesives may be used uniformly orin the form of a continuous or noncontinuous layer.

The cover layer may be designed in two parts. Two parts here means thatthe cover layer may consist of an outer area and a central area. Theouter area is preferably essentially in the area of the longitudinaledges of the absorbent article and, if there are wings on the napkin, itmay also be designed in the area of the wings, where the central area isdesigned in the remaining central area of the absorbent article. The twoparts of the cover layer can be bonded together. Such a bond can beproduced by using a hot-melt adhesive or by providing a welded seam.Other forms of bonds that are known in this field of the art are alsoincluded here.

If the cover layer is designed in two parts, the central area of thecover layer and/or the outer area of the cover layer may be a spunbondednonwoven of polypropylene having an especially thick fiber and thus ahigh denier. Furthermore, this spunbonded nonwoven may contain morepigment, e.g., have a higher titanium dioxide content to improve themasking properties. Such a polypropylene spunbonded nonwoven with theproperties described above may have, for example, a basis weight of 15to 50 g/m² preferably 20 g/m². In a preferred embodiment, it is 70 mmwide.

Other possible materials for the outer area of the cover layer and/orthe inner area of the cover layer include spunbonded nonwovens or cardednonwovens of polypropylene, for example, with a basis weight of 15 to 50g/m², preferably 20 g/m². The preferred composition of the cover layeris a two-part cover layer, where the outer area of the cover layer ismade of a polypropylene spunbonded nonwoven with a basis weight of 20g/m², and where the inner area of the cover layer is made of aperforated polypropylene spunbonded nonwoven in a weight of 20 g/m². Thetwo parts of the cover layer are preferably bonded by a welded seam.

The backing layer may be made of any desired material that isliquid-impermeable. The backing layer preferably allows atmosphericvapor and moisture to pass through the absorbent article whilepreventing body fluid from passing through. A suitable material is amicroembossed polymer film such as polyethylene or polypropylene with anapproximate thickness of 0.025 to 0.13 mm. Two-component films may alsobe used, as well as nonwoven materials or woven materials which aretreated to make them liquid impermeable. Other suitable materialsinclude films filled with CaCO₃ or polyolefin in foams. A polyethylenefoam with a thickness in the range of approximately 0.5 mm toapproximately 10 mm can be mentioned as an example.

The absorbent body in the absorbent article provides a means forabsorbing the secreted fluid, in particular menstrual fluid. The totalabsorption capacity of the absorbent body should correspond to theanticipated loading in the course of the intended use of the absorbentarticle. In addition, the size and shape of the absorbent body may vary.As explained above, the absorbent body may have the various shapesmentioned above in the area of the minimum of one layer of the absorbentbody facing the wearer's body. The minimum of one layer of the absorbentbody facing away from the wearer's body may also have various shapes,but at any rate it should be larger than the minimum of one layer facingthe wearer's body. It can function as a secondary reservoir. The layerof the absorbent body facing away from the wearer's body may be, forexample, rectangular with rounded longitudinal edges, tongue-shaped oroval or it may have any other known geometric shape known in the relatedart.

The absorbent body is generally made of one or more materials whichtogether are essentially hydrophilic, compressible, adaptable andnon-irritating for the skin of the wearer. Suitable materials are wellknown in the field and include, for example, various natural orsynthetic fibers, cellulose fibers, regenerated cellulose or cottonfibers or a blend of cellulose and other fibers, melt-blown polymerssuch as polyester and polypropylene. The absorbent layers may alsoinclude other well-known materials which are used with absorbentarticles, including several layers of a cellulose filling, rayon fibers,cellulose sponge, hydrophilic synthetic sponges, such as polyurethaneand the like.

In addition, especially when used in incontinence articles, theabsorbent body may contain superabsorbers which are very effective inretaining body fluids. Superabsorbers have the ability to absorb a largeamount of fluid in relation to their own weight. Typical superabsorbersused in absorbent articles such as sanitary napkins can absorb betweenapproximately 5 and 60 times their weight in body fluids.

A preferred material for the absorbent layer is a coform material whichcontains, for example, cellulose and polypropylene in a weight ratio of70:30 and has a basis weight of 150 g/m² and is used together with apolypropylene spunbonded nonwoven backing with a basis weight of 17g/m². As an alternative, for example, a coform material containingcellulose and polypropylene in a weight ratio of 60:40 and having abasis weight of 90 g/m² may also be used together with a polypropylenespunbonded nonwoven backing with a basis weight of 20 g/m².

Another layer may be provided on the side of the absorbent body facingthe wearer's body, acting as the transfer layer and transfers the fluidto the absorbent body in a suitable manner. This transfer layer ispreferably punched or cut out in the same way as the minimum of one partof the absorbent body facing the wearer's body. This transfer layerespecially preferably has an open structure which is especiallypermeable for fluids and has large pores but a low density. For example,laminates of spunbonded nonwoven and carded nonwovens are suitable, withthe fluffy side facing up. Such a transfer layer may also have alaminating function (dry and clean).

The transfer layer and/or the minimum of one layer of the absorbent bodyfacing the wearer's body can be differentiated visually from the rest ofthe sanitary napkin, for example by using a different color for thetransfer layer and/or the minimum of one layer of the absorbent bodyfacing the wearer's body than for the rest of the absorbent article.

The transfer layer and/or the minimum of one layer of the absorbent bodyfacing the wearer's body are preferably punched or cut out and appliedto one or more other absorbent layer(s) of the absorbent body,preferably made of coform, and preferably bonded together by one of thepossible methods mentioned above.

Although the transfer layer and/or the upper layer of the minimum of onelayer of the absorbent body facing the wearer's body may have alaminating function, this laminating function may also be assumed,instead or in addition, by the cover layer. The cover layer may in thiscase contain approximately 1% to 6% titanium dioxide pigment and mayhave a clean and attractive appearance.

In another preferred embodiment of this invention, the liquid-permeablecover layer may also have a plurality of openings which are formed init. The size of these openings should be such that a fluid can passthrough the cover layer and thereby enter the absorbent body. Theopenings may be arranged in a longitudinal direction or may be localizedin larger numbers in a certain area, which is assumed to be the areathat will come in contact with the fluid. The openings should increasethe rate at which the body fluids can reach the absorbent body. Thisfacilitates providing a much drier surface for the cover layer than ifthe openings were not present.

The part of the absorbent body facing the wearer's body may preferablyhave embossed lines through which the fluid is guided along especiallypreferred pathways. These embossed lines may also be provided in thetransfer layer and/or individual or all of the other layers of theabsorbent body.

The cover layer may also be treated with a surfactant to make it morehydrophilic and thus support the absorption of fluid. The surfactant maycontain topical additives or internally added materials such aspolysiloxanes.

Furthermore, the absorbent article may have another layer on the side ofthe absorbent body facing away from the wearer's body to act as adistributing layer. In a preferred embodiment, this distributing layeris folded. It may serve as the primary reservoir. It advantageouslycontains especially small pores and thus has the greatest capillarity inthe system of the preferred absorbent article according to the presentinvention. A melt-blown fiber layer is especially preferably used forthe distributing layer. This melt-blown layer of polypropylene, forexample, may have a basis weight of 65 g/m² and in a preferredembodiment it is folded to a final width of 45 mm and a length of 125mm.

Some or all of the individual layers of the absorbent article may bebonded together in some areas or in totality. In a preferred embodiment,their bonding can be accomplished by using a hot-melt adhesive. Otherbonding methods known in the related art, however, should also beincluded within the scope of the present patent application.

In another preferred embodiment of this invention, the absorbent articleaccording to the present invention has wings on its longitudinal sideedges, where the minimum of one layer of the absorbent body facing awayfrom the wearer's body may continue into these wings but need notnecessarily extend into these wings. The wings and the longitudinal bodyof the absorbent article may be provided with a longitudinal adhesivesystem consisting of a hot-melt adhesive, for example, with a preferredarea of 50×190 mm for the longitudinal body of the absorbent article anda preferred area of 20×50 mm for the respective wing adhesive systems ofthe absorbent article. The longitudinal adhesive system and the wingadhesive systems are each preferably covered by silicone paper or someother possible covering which is known in the state of the art.

The absorbent article according to the present invention is preferablyused as a sanitary napkin or as an incontinence diaper.

Furthermore, the absorbent body according to the present invention mayinclude a flow layer and a reservoir layer in a manner familiar to thoseskilled in the art. Suitable flow layers are made, for example, ofcellulose, cellulose-synthetic fiber blends such as coform materials,airlaid-cellulose-synthetic fiber blends, foam materials or high-loftnonwovens and they may contain superabsorbers as an additionalcomponent.

Suitable reservoir layers are characterized, for example, by thematerials mentioned above for the absorbent body. In an especiallypreferred embodiment, the minimum of one layer of the absorbent bodyfacing the wearer's body acts as a flow layer.

The absorbent article according to the present invention especiallypreferably has a density and/or pore gradient. The layer next to thebody has the lowest density and the layer next to the liquid-impermeablebacking layer has the greatest density.

This facilitates diversion of fluid away from the wearer's body.

Such a density and/or pore gradient can be produced in a manner known tothose skilled in the art, e.g., by using materials of differentdensities or by using different pore sizes, etc.

In another aspect, the present invention provides a method of producingan absorbent body, in particular a segmented absorbent body. Theseabsorbent bodies are used in particular in the absorbent articlesaccording to this invention.

A first method according to this invention includes the following steps:a first web of material is brought over a first rotating conveyorelement; the first web of material is processed for separation by asecond rotating conveyor element along a closed line, creating a firstclosed dividing seam through the entire thickness of the first web ofmaterial; the part of the first web of material outside the firstdividing seam is conveyed away over the first rotating conveyor element;the minimum of one part of the first web of material bordered by thefirst dividing seam is conveyed further with the second rotatingconveyor element; a second web of material is conveyed over a thirdrotating conveyor element; the minimum of one part of the first web ofmaterial bordered by the first dividing seam is deposited on the secondweb of material, and the second web of material is processed forseparation by the second rotating conveyor element along the peripheralshape of the minimum of one part of the first web of material borderedby the first dividing seam, thereby creating a minimum of one secondself-contained dividing seam through at least partial areas of thethickness of the second web of material, and the minimum of one firstand second self-contained dividing seam essentially coincide.

The first web of material and the second web of material may compriseindividual materials or multiple materials.

The first web of material and the second web of material may each becomposed of one or more layers which may preferably be bonded togetherwith adhesive and which may consist of different materials. The firstweb of material may comprise in particular layers of the materials usedin the minimum of one layer of the absorbent body facing the wearer'sbody as well as the transfer layer of the absorbent article according tothis invention.

The second web of material may comprise in particular layers of thematerials used in the minimum of one layer of the absorbent body facingaway from the wearer's body and the distributing layer of the absorbentarticle according to this invention.

The term “self-contained dividing seam” as used in the present inventionis understood to refer to dividing seams which define an internal closedgeometric shape in a web of material.

The minimum first and second self-contained dividing seams may assumeany suitable geometric shape, but the especially preferred shapes are anoval, a triangle, a circle, a tongue or an hourglass. The shape of thelayer of the absorbent body facing the wearer's body in the finishedabsorbent article according to this invention is determined by the shapeof the first dividing seam.

In an especially preferred embodiment of the method according to thisinvention, the second web of material and the minimum of one partdeposited on the former and bordered by the first dividing seam isseparated into individual units in another step, with each unitcomprising a part of the first web of material bordered by the firstdividing seam and a frame grid formed by the second web of material.

The term “frame grid” as used here, by analogy with the articlesaccording to this invention described here, is understood to be the partof the material of the absorbent material which remains outside thesecond dividing seam. The frame grid thus corresponds, for example, tothe part of the layer of the absorbent article according to thisinvention facing away from the wearer's body outside the second dividingseam. The frame grid includes the area of the second web of materialdefined by the second dividing seam.

In another preferred embodiment of the two methods according to thisinvention as described here, the individual steps of the method arerepeated continuously.

In an especially preferred embodiment of the method according to thepresent invention, the first web of material is conveyed at a ratecorresponding to the peripheral speed of the second conveyor element.This embodiment of the method can be used in particular with theabsorbent articles produced according to this invention, when thedifference in length between the part of the web of material bordered bythe first line, corresponding to the layer of the absorbent body facingthe wearer's body and the frame grid formed by the second web ofmaterial or the layer of the absorbent body facing away from thewearer's body is not very great, e.g., amounting to less than 25%.

One embodiment of the method according to this invention in which thefirst web of material is conveyed intermittently and the second rotatingconveyor element rotates continuously is especially preferred.

This has the advantage that the cost of materials can be minimized. Dueto the intermittent conveyance of the first web of material over thefirst rotating conveyor element with a second conveyor element rotatingcontinuously at the same time, the first self-contained dividing seamscan be worked into the first web of material in a closer sequence insuccessive separation processing steps than if the first and secondconveyor elements were running continuously in synchronization.Therefore, the amount of the first web of material used for theabsorbent article can be increased, and the amount of the first web ofmaterial discarded and thus the amount of waste can be minimized.

This process management is especially preferred if the difference inlength between the layer facing the wearer's body and the layer facingaway from the wearer's body is relatively great in the absorbent articleproduced, e.g., greater than 25%. In these cases, due to the moreeffective utilization of the first web of material, the method can beless expensive. Intermittent conveyance is understood here to refer toboth conveyance at two different successive speeds and interruptedconveyance in phases.

In a most especially preferred embodiment of the method according tothis invention, the first and second rotating conveyor elements run insynchronization during the separation working of the first web ofmaterial. This has the advantage that the shape of the minimum of onepart of the first web of material bordered by the first dividing seamcorresponds exactly to the shape of the second dividing seam in thesecond web of material, when the same dividing elements are used for thetwo separation processing steps.

In another especially preferred embodiment of the method according tothis invention, the rotating conveyor elements are designed in the formof rolls or wheels. These designs permit an especially simple andinexpensive embodiment of this method.

In another especially preferred embodiment of the method according tothis invention, the first web of material is processed for separation bymeans of at least one separating element mounted on the second rotatingconveyor element.

It is also especially preferred for the second web of material to beprocessed for separation by means of at least one separating elementmounted on the second rotating conveyor element.

This makes it possible to mount similar separating elements on thesecond rotating conveyor element, which is especially economical.

The separating element may be, for example, all known cutting orpunching devices with which those skilled in the art are familiar. Theymay be mounted on the second conveyor element in a fixed mount or sothey can be telescoped outward.

Due to the fact that the minimum of one part of the first web ofmaterial bordered by the first dividing seam is deposited on the secondweb of material by means of the second conveyor element, this yields acomposite web of material in which a particular structure is preformed.In subsequent separation of the composite web of material into separateindividual units, these units each include a top layer and a bottomlayer, with the top layer having a smaller surface area than the bottomlayer, and the bottom layer having a dividing seam corresponding to theshape of the top layer.

In another especially preferred embodiment of the method according tothis invention, in another step, the second web of material and theminimum of one part of the first web of material, bordered by the firstdividing seam and deposited on the second web, are divided intoindividual units, with each unit comprising a part of the first web ofmaterial bordered by the first dividing seam plus a frame grid formed bythe second web of material.

In an especially preferred embodiment of the method according to thisinvention, an adhesive layer is applied at least to partial areas of thesecond web of material in order to bond the second web of materialadhesively to at least parts of the first web of material. It isespecially preferable to provide an adhesive layer only on those areasof the second web of material where the minimum of one part of the firstweb of material bordered by the first dividing seam has been deposited.

In an especially preferred embodiment of the method according to thisinvention, a reduced pressure is created in an area of the secondconveyor element to support the conveyance of the minimum of one part ofthe first web of material bordered by the first dividing seam on thesecond conveyor element.

It is advantageous here to design the second conveyor element as ahollow wheel or roller, where the conveyor element designed to be hollowis preferably subdivided into angular segments by at least one innerbulkhead, and these angular segments may be acted upon by pressureindependently of one another in the form of a reduced pressurereservoir, a balanced pressure reservoir or an excess pressurereservoir. The segment of the conveyor element with which the web ofmaterial is conveyed is preferably acted upon by reduced pressure.

As an alternative, however, other methods known to those skilled in theart may also be used to support or accomplish the adhesion of the web ofmaterial to the second conveyor element and, thus, conveyance of the webof material.

In addition, in another especially preferred embodiment of the methodaccording to this invention, deposition of the part of the first web ofmaterial bordered by the first dividing seam onto the second web ofmaterial can be accomplished or supported by an excess pressure producedin the area of the second conveyor element.

Deposition of the part of the first web of material bordered by thefirst dividing seam on the second web of material is supported oraccomplished by applying an excess pressure to a suitable angularsegment of the conveyor element.

As an alternative, deposition of the part of the first web of materialbordered by the first dividing seam onto the second web of material canbe supported or accomplished by an elastic ejector.

In another especially preferred embodiment of the method according tothis invention described here, several first and second self-containeddividing seams are worked side-by-side into the first and/or second websof material in spaced apart relationship. This has the advantage thatwider webs of material can be used and thus, higher piece numbers of theabsorbent articles can be produced per unit of time.

Although the minimum of one first dividing seam always extendsthroughout the entire thickness of the first web of material, and thusthe forms described above are separated from the first web of material,the second dividing seam can extend throughout the entire thickness ofthe second web of material, or only through partial areas of thethickness of the second web of material. Thus, in the latter case, anintended breaking line is created in the material of the second web ofmaterial.

In the absorbent article produced by the method according to thisinvention, the shape of the layer of the absorbent body facing thewearer's body is determined by the minimum of one first dividing seam.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described in detail with the help ofthe accompanying figures, where:

FIG. 1 is a top view of a preferred embodiment of the present invention;

FIG. 2 is cross section through a preferred embodiment of the presentinvention;

FIG. 3 is a perspective view of a preferred embodiment of the presentinvention in a partially cutaway view;

FIGS. 4 through 7 are preferred segmentations in an absorbent body whichcan be used in preferred embodiments of the present invention;

FIG. 8 is a device for carrying out the method of producing an absorbentarticle;

FIG. 9 is another device for carrying out the method of producing anabsorbent article; and

FIGS. 10 a through k are especially preferred shapes and punchedpatterns of the layer of the absorbent body facing the wearer's body.

The reference numbers used in the figures have the following meanings:

-   -   1: outer cover layer    -   2: hot-melt adhesive    -   3: central cover layer    -   4: transfer layer    -   5: layer of the absorbent body facing the wearer's body    -   6: layer of the absorbent body facing away from the wearer's        body    -   7: distributing layer    -   8: backing layer    -   9: wing adhesive system    -   10: covering of the wing adhesive system    -   11: longitudinal body adhesive system    -   12: covering of the longitudinal body adhesive system    -   13: welded seam    -   14: wing    -   15: dividing seam    -   20: first conveyor element    -   21: second conveyor element    -   22: separating element    -   24: third conveyor element    -   25: first web of material    -   26: second web of material    -   28: first self-contained dividing seam    -   29: second self-contained dividing seam    -   30: part of the web of material bordered by the first dividing        seam    -   31: part of the first web of material outside the first dividing        seam    -   33: loop forming roller    -   35: loop forming roller    -   36: tension rollers    -   37: tension rollers    -   38: d.c. motor    -   39: reduced pressure area    -   40: screen    -   41: excess pressure area    -   42: adhesive device    -   43: adhesive layer    -   45: width adjusting roller    -   46: draw-off roller    -   47: web width    -   48: composite web    -   50: absorbent body

DETAILED DESCRIPTION OF THE DRAWINGS

The sanitary napkin illustrated in FIGS. 1 and 2 has essentially anhourglass shape with wings 14 that project outwards being formed in themiddle of the longitudinal sides and which are tapered toward themiddle. The length of the sanitary napkin may be 238 mm, for example,and the width including the two wings 14 is 150 mm, for example. The toplayer of the sanitary napkin is formed by an outer cover layer 1 and acentral cover layer 3. The central cover layer 3 extends along a centralstrip over the entire length of the sanitary napkin. The width of thecentral cover layer 3 may be 70 mm, for example. The central cover layeris made of a perforated polypropylene spunbonded nonwoven with a basisweight of 20 g/m².

The outer cover layer 1 overlaps with the central cover layer 3 and isbonded to it in the overlap area. This bonding can be accomplished by awelded seam, for example. As an alternative, the two cover layers 1 and3 may also be bonded together by a hot-melt adhesive. The outer coverlayer is also made of a perforated polypropylene spunbonded nonwovenwith a basis weight of 20 g/m².

The multi-layer absorbent body of the sanitary napkin is located beneaththe central cover layer. In the advantageous embodiment of thisinvention described here, the absorbent body includes as the top layerthe transfer layer 4. The layer of the absorbent body 5 facing thewearer's body is beneath the transfer layer 4 and may also be referredto as an absorbent core. The layer of the absorbent body 6 facing awayfrom the wearer's body is also arranged beneath the layer 5 with thedistributing layer 7 arranged beneath it.

The transfer layer 4 is bonded to the central cover layer 3 over itsupper surface by means of a hot-melt adhesive 2. The transfer layer 4consists of a laminate of a spunbonded nonwoven and a carded nonwovenwith a basis weight of 52 g/m² and is arranged in such a manner that thefluffy side of the laminate faces upward, i.e., in the direction of thewearer's body. In addition, the transfer layer is differentiated incolor from the remainder of the sanitary napkin.

The layer of the absorbent body 5 facing the wearer's body is arrangedbeneath the transfer layer 4. The transfer layer 4 and the layer of theabsorbent body 5 facing the wearer's body are bonded together by meansof a hot-melt adhesive 2. The transfer layer 4 and the layer of theabsorbent body 5 facing the wearer's body are punched out in the form ofan oval in the present advantageous embodiment of this invention, andthey are arranged in the central area of the sanitary napkin. The ovalshape has a length of 110 mm, for example, and a width of 45 mm. Thelayer of the absorbent body 5 facing the wearer's body is made of acoform material, for example, containing cellulose and polypropylene ina weight ratio of 70:30 and having a basis weight of 150 g/m². It isused together with a spun-bonded nonwoven carrier of polypropylene witha basis weight of 17 g/m². The laminate of coform material andspunbonded nonwoven carrier has a line embossing with compressed areas.

Especially preferred shapes of layer 5 facing the wearer's body whichmay be used as an alternative to the oval shape are illustrated in FIGS.10 a-k. In addition, the layers 5 of the absorbent body facing thewearer's body, as shown in FIGS. 10 a-k, have internal dividing seams 15which further segment the layers 5. These dividing seams also may beprovided in the same way in layers 4, 6, 7 of the absorbent body aboveand/or beneath that.

The layer of the absorbent body 6 facing away from the wearer's body isarranged beneath the layer of the absorbent body 5 facing the wearer'sbody. The layer of the absorbent body 6 extends essentially over thesame area as the central cover layer 3, but is shorter in the area ofthe rounded transverse ends of the sanitary napkin, so that the centralcover layer 3 projects over the layer of the absorbent body 6 facingaway from the wearer's body in this area. The layer of the absorbentbody 6 facing away from the wearer's body may be 220 mm long and 70 mmwide, for example, and made of a coform material of cellulose andpolypropylene in a weight ratio of 60:40 and with a basis weight of 90g/m². It is used together with a spunbonded nonwoven carrier ofpolypropylene with a basis weight of 20 g/m².

An oval punched area provided in the central area of the layer of theabsorbent body 6 facing away from the wearer's body corresponds in sizeand shape to the layer of the absorbent body 5 facing the wearer's bodyand to the transfer layer 4. Due to the punched area, the layer of theabsorbent body 6 facing away from the wearer's body is divided into aninner area and an outer area. The outer area represents the frame grid.The inner oval area of the layer of the absorbent body 6 facing awayfrom the wearer's body lies with complete coverage beneath the layer ofthe absorbent body 5 facing the wearer's body. The top surface of thelayer of the absorbent body 6 facing away from the wearer's body isbonded to the central cover layer 3 by means of a hot-melt adhesive 2 inthe area not covered by the layer of the absorbent body 5 facing thewearer's body.

In the central area of the sanitary napkin, the distributing layer 7 isarranged beneath the layer of the absorbent body 6 facing away from thewearer's body. The distributing layer 7 is made of a web of embossedmelt-blown material of polypropylene with a basis weight of 65 g/m²folded on itself to yield a final width of 45 mm with a length of 125mm, for example. A liquid-impermeable backing layer 8 arranged beneaththe distributing layer 7 is made of a polyethylene film with a basisweight of 25 g/m². The liquid-impermeable backing layer prevents thefluid that has penetrated into the sanitary napkin and been retainedthere from escaping outward from the absorbent layers at the bottom. Thebacking layer 8 is bonded to the layer of the absorbent body 6 facingaway from the wearer's body and to the central cover layer 3 and theouter cover layer 1 by means of a hot-melt adhesive 2.

In the area of the wings 14, wing adhesion systems 9 are provided on theouter surface of the backing layer 8 facing away from the wearer's body;by means of these wing adhesion systems, the wings 14 can be attached tothe side of the wearer's underwear facing away from the wearer's body.The adhesive material may be, for example, a hot-melt adhesive. Toprotect the adhesive surfaces of the wing adhesion systems 9, they areprovided with a covering 10 of silicone paper which can be removed fromthe adhesive elements before using the sanitary napkin. Before use, thetwo wings 14 and the side areas of the sanitary napkin can be foldedonto the central cover layer 3, so that the wing adhesion systems 9 cometo lie side by side. The two wing adhesion systems 9 may then be coveredwith the covering 10 of silicone paper which may have an area of 70mm×60 mm, for example.

Additional fixation of the sanitary napkin to the wearer's underwear ismade possible by the longitudinal body adhesive system 11 which extendsover the central area of the outer surface of the backing layer 8 overan area of 50 mm×190 mm. The sanitary napkin can be attached to theinside of the wearer's underwear with the longitudinal body adhesivesystem 11. The longitudinal body adhesive system 11 may also be formedby a hot-melt adhesive, for example, and is protected by a secondcovering 12 which is detachably attached to it. The covering 12 of thelongitudinal body adhesive system is also made of silicone paper and hasan area of 60 mm×200 mm. The covering 12 is removed before using thesanitary napkin, thus exposing the adhesive surface of the longitudinalbody adhesive system 11.

FIGS. 4 through 7 illustrate various segmentation patterns which can beprovided in the absorbent body 50 or individual layers of the absorbentbody 50 of the absorbent article. FIG. 4 illustrates a squaresegmentation and FIG. 5 illustrates rhomboidal segmentation. FIG. 6shows the segmentation in the form of a plurality of circular dividingseams 15.

When using an oval-shaped minimum of one layer 5 of the absorbent bodyfacing the wearer's body, the segmentation illustrated in FIG. 7 of atleast one of the layers 4, 6, 7 of the absorbent body 50 arranged aboveand/or beneath it is especially advantageous. Due to the dividing seams15 extending radially outward from the oval peripheral shape of theminimum of one layer 5 of the absorbent body facing the wearer's body(soleil notching), an especially easy basket shaping of the absorbentarticle and thus improved suppleness (body fit) to the wearer's body areachieved.

FIG. 8 illustrates a device for carrying out the method according tothis invention.

A first running web of material 25 of absorbent material is conveyedover a conveyor unit (not shown here), e.g., driven conveyor rolls orbelts or rollers to two loop-forming rollers 33, 35. A supply loop ofthe first web of material 25 is formed by the two loop-forming rollers33, 35.

As an alternative, instead of the loop-forming rollers 33, 35, otherstorage devices with which those skilled in the art are familiar mayalso be used. The first web of material 25 is then conveyed over twotension rollers 36, 37 that are synchronized but driven intermittentlyto the first conveyor element 20. The first conveyor element 20 isdesigned here as a counter-cutting roller. The irregular or intermittentdrive of the tension rollers 36, 37 is accomplished by an electronicallycontrolled d.c. motor, but it may also be provided by other means suchas a corresponding hydraulic or mechanical system. For example, it isalso conceivable to use cams or disks.

The first web of material 25 is guided between the mating cutting roller20 and a second conveyor element 21 which is designed here as a cuttingroller 21. The cutting roller 21 is subdivided into segments in itsinterior by an internal bulkhead, for example, thus forming an area 39which is acted upon by a reduced pressure and an area acted upon by anexcess pressure. The internal bulkhead here is stationary, whereas theouter shells of the roller are rotating. Mesh-like screens 40 areapplied to the outer shell of the cutting roller 21 at regular intervalsalong the circumference of the roller, so that the excess pressure orreduced pressure can act on the respective parts of the web of materialabove the screens 40. Due to the rotation of the outer shell of thecutting roller 21 either a reduced pressure or an excess pressure canact in the area of each screen 40. Individual separating elements 22 arearranged around each screen 40. These separating elements here aredesigned as punching devices; as an alternative, however, cuttingdevices may also be used. Those skilled in the art are familiar withsuitable cutting or punching devices. Individual areas 30 of the firstweb of material are punched out by the punching devices 22 and areconveyed further on the cutting roller 21 by the reduced pressure actingthrough the screens 40 in the punched area.

The parts 30 of the web of material bordered by the first dividing seamin the method described here are oval. They are referred to below as theabsorbent core 30. The part 31 of the first web of material outside thefirst dividing seam, i.e., the punched grid, is conveyed away afterpunching over the mating cutting roller 20 and a width adjusting roller45 and draw-off roller 46. The first web of material 25 is undercontinuous tension due to the width adjusting roller 45 and the draw-offroller 46.

Due to the intermittent drive of the tension rollers 36, 37, the firstweb of material 25 reaches a speed corresponding to the peripheral speedof the cutting roller 21 only during the punching operation. Therefore,the distance between two punched-out areas in the punched grid, referredto here as the web width 47, can be kept as small as possible. This isespecially advantageous if the absorbent cores 30 are deposited onto thesecond web of material at a relatively great distance from one another,e.g., if this distance exceeds the length of the absorbent cores 30 by25%.

A third conveyor element 24 is arranged next to the cutting roller 21 ata distance from the first mating cutting roller 20 in the direction ofproduction. This third conveyor element is also designed as a secondmating cutting roller 24. A second web of material 26, also an absorbentmaterial, is conveyed over an unwinder (not shown) and between thecutting roller 21 and the second mating cutting roller 24. Due to thepunching devices 22 mounted on the cutting roller, punched areas arebeing worked into the second web of material continuously, havingessentially the same shape and size as the punched absorbent cores 30punched out of the first web of material 25. The absorbent cores 30 aredeposited on the second web of material 26 simultaneously with thepunching operation. To do so, the internal segmentation of the cuttingroller is designed so that an excess pressure 41 acts on thecorresponding absorbent core 30 through the corresponding screen 40during the punching operation. By simultaneously depositing theabsorbent cores 30 on the second web of material and punching the secondweb of material 26, the result is that the second web of material ispunched in the resulting composite web 48 along the contours of theabsorbent cores 30 deposited on the web.

Adhesion between the absorbent cores 30 and the second web of materialis supported by application of adhesive 43 by an adhesive device 42before punching.

An intermittent drive of the first web of material is not necessary ifthe distance between two successive absorbent cores 30 exceeds its ownlength by only less than 25%. The elasticity of the first web ofmaterial here makes it possible for the first web of material to beconveyed towards and away at a lower speed than the peripheral speed ofthe cutting roller 21. Therefore, it is also possible to reduce theamount of the punched grid in the first web of material. FIG. 9illustrates a method in which two methods as described above arecombined in succession. In the method illustrated here, the compositeweb 48 produced in the first method is used as the second web ofmaterial in the successive method.

This makes it possible to deposit additional absorbent cores 30′ punchedout of a third web of material onto the composite web 48 incorresponding manner and then to segment the composite web 48 throughadditional punching. The absorbent cores 30′ deposited on the compositeweb 48 in the subsequent procedure may have the same or different shapesand sizes as the absorbent cores 30 punched out of the first web ofmaterial and already deposited on the composite web.

What is claimed is:
 1. A method of producing an absorbent body for anabsorbent article of the type worn by a wearer and having an absorbentbody disposed generally centrally of said article and adapted forabsorbing liquid body waste released by the wearer, the methodcomprising the steps of: passing a first cut-out from a first webmaterial through a nip; passing a second web material through the nipwhereby the cut-out from the first web material overlays the second webmaterial as the cut-out and the second web material pass through thenip; and performing one of the following as the cut-out from the firstweb material and the second material together pass through the nip:forming a fold line in the second web material at the peripheral edge ofthe cut-out of the first web material and forming a second cut-out fromthe second web material having substantially the same shape as the firstcut-out from the first web material.
 2. A method as set forth in claim 1wherein the nip is defined by a pair of conveyor elements, the step ofpassing the second web material through the nip comprising conveying thesecond web material over one of said conveyor elements to passtherebetween, at least one of said conveyor elements having one of afold-line forming device and a cutting device mounted thereon forcontacting the second web element at the peripheral edge of the cut-outfrom the first web-material generally within the nip.
 3. A method as setforth in claim 2 wherein the pair of conveyor elements are second andthird conveyor elements defining the nip therebetween, the secondconveyor element having said one of a fold-line forming device and acutting device mounted thereon, the method further comprising the stepsof conveying a first web material over a first conveyor element to a nipdefined by the first conveyor element and the second conveyor element,and contacting the first web of material with said one of a fold-lineforming device and a cutting device mounted on the second conveyorelement with sufficient pressure to form the first cut-out from thefirst web material as the first web material passes through the nipformed by the first and second conveyor elements, the step of passingthe first cut-out from the first web of material through the nipcomprising supporting the first cut-out on the second conveyor elementupon rotation of the second conveyor element to convey the first-cut outto the nip formed by the second and third conveyor elements.
 4. A methodas set forth in claim 3 wherein the first and second conveyor elementsare rotating elements from the group consisting of rollers and wheels,the first web of material being conveyed through the nip defined by thefirst and second conveyor elements at a speed equal to the rotationalspeed of the second conveyor element.
 5. A method as set forth in claim3 wherein the first and second conveyor elements are rotating elementsfrom the group consisting of rollers and wheels, the first web ofmaterial being conveyed through the nip defined by the first and secondconveyor elements intermittently while the second rotating conveyorelement rotates continuously.
 6. A method as set forth in claim 1further comprising the step of applying adhesive to at least one of thefirst cut-out from the first web material and the second web materialprior to passing the first cut-out and the second web material throughthe nip such that the first cut-out is secured to the second webmaterial upon passing through said nip.
 7. A method as set forth inclaim 3 wherein the step of supporting the first-cut on the secondconveyor element as the first cut-out is conveyed to the nip formed bythe second and third conveyor elements comprises applying a vacuumpressure to the first cut-out to hold the first cut-out on the secondconveyor element during rotation of the second conveyor element.
 8. Amethod as set forth in claim 7 wherein the first cut-out is releasedfrom the second conveyor element onto the second web material bysubjecting the first cut-out to a positive pressure.